Method for forming package

ABSTRACT

An improved bathtub shipping package for completely encircling the bathtub to protect the bathtub from rough handling and the elements of weather. The package comprises a wrap-around tube member having a pair of unique end caps fixedly attached to the tube member, the end caps having built in means for reinforcing the end caps from horizontal and vertical shock as well as built in protective pads for protecting the top end portions of the bathtub whenever the bathtub is placed within the package. The structural manufactured joint for the tube member is formed at the bottom rear of the tube which serves to cushion the rear legs of the bathtub whenever the bathtub is placed within the package. The end caps are positioned within the tube in combination with the structural manufactured joint so that longitudinal stapling of the end caps to the tube member is easily accomplished due to the resistance of the structural manufactured joint.

United States Patent [1 1 Coons et al.

[ METHOD FOR FORMING PACKAGE [75] inventors: Everett A. Coons, West Monroe,

La.; Lewis 1). Poggiali; Richard P. Jacalone, both of Owosso, Mich.

[731 Assignee: Olinkraft, Inc., West Monroe, La. 22 Filed: Ma 'zs, i973 [21] Appl. No.: 363,948

Related U.S. Application Data [62] Division of Ser. No. 223,582, Feb. 4, 1972, Pat. No.

93/36 M, 41, 41.1, 55.1 M, 55.1 P, 94 M, 94 PS; 229/23 R, 23 A, 37 E {56] References Cited UNlTED STATES PATENTS 2,404,067 7/1946 Hill 229/23 R 2,597,848 5/1952 Reeser 229/23 R X 3,194,395 7/1965 Weaver et al.... 206/46 H 3,289,825 12/1966 Smith 206/46 H 3,307,767 3/1967 Humphrey 229/23 R X 3,486,612 12/1969 Kivell 206/46 H 3,521,744 7/1970 Smith 206/46 H 3,572,575 3/1971 Dorofachuk 229/37 E June 4, 1974 3,680,688 8/1972 Smith 206/46 H Primary Examiner-Travis S. McGehee Assistant Examiner-J. Sipos Attorney, Agent, or Firm--Norve11 E Von Behren [57] ABSTRACT An improved bathtub shipping package for completely encircling the bathtub to protect the bathtub from rough handling and the elements of weather. The package comprises a wrap-around tube member having a pair of unique end caps fixedly attached to the tubevmember, the end caps having built in means for reinforcing the end caps from horizontal and vertical shock as well as built in protective pads for protecting the top end portions of the bathtub whenever the bathtub is placed within the package. The structural manufactured joint for the tube member is formed at the bottom rear of the tube which serves to cushion the rear legs of the bathtub whenever the bathtub is placed within the package. The end caps are positioned within the tube in combination with the structural manufactured joint so that longitudinal stapling of the end caps to the tube member is easily accomplished due to the resistance of the structural manufactured joint.

3 Claims, 12 Drawing Figures PATENTEDJun 4 I974 SHEU 1 0F 4 lOl FIG. 2

PATENTEDJUH 4mm I 3.813344 FIG.|| FIG.I2

METHOD FoR FORMING PACKAGE This is a division, of application Serial No. 223,582 filed February 4, 1972 now Patent No. 3,757,935.

BACKGROUND OF THE INVENTION This invention relates generally to paperboard containeis and more particularly relates to a new and improved bathtub shipping package which may be constructed in a three-piece construction to eliminate standard conventional heavy and/or bulky shipping containers.

In the handling of residential bathtubs formed of pressed steel, special problems are encountered in preparing the bathtubs for shipping and storage due to the large heavy size of the bathtubs as well as their finished surfaces which must be free from damage when installed in the ultimate users home-Prior art bathtub containers are known which are formed bymanufacturing a wooden crate and placing the bathtub therein for shipment to the consumer. One such bulky bathtub container is shown in the U.S. Pat. No. 3,099,351 issued on July 30, 1963 to Coffey. Bathtub containers such as this while protecting the bathtub during the trip to the consumer, often increase the handling problems of the tub due to the extra weight encountered with the use of the heavy wooden frame used to surround the tub.

Thereafter efforts were made to reduce the weight of the heavy wooden crates by the use of a combination of wood and paperboard without destroying the effectiveness of the protection afforded by the container. One such effort is shown in U.S. Pat. No. 3,194,395 issued July 13, l965 to Weaver et al. wherein a combination of wooden end caps are used in conjunction with paperboard top and bottom panels which are banded to the wooden end caps at the end of the package. Such a package, while serving its ultimate purpose, still required a fabrication of heavy wooden end caps which added greatly to the cost of the entire package. Further attempts at reducing the cost of the package resulted in the configuration shown in U.S. Pat. No. 3,487,914 issued Jan. 6, 1970 to Weaver et al. which attempted to eliminate the wooden end caps by the use of paperboard end caps but which still required wooden reinforcements in the end caps in order to obtain the necessary structural stability-and cushioning necessary for the bathtub package.

Other attempts have been made to utilize an all paperboard shipping package as shown by the U.S. Pat. No. 3,289,825 issued Dec. 6, 1966 toSmith and the U.S. Pat. No. 3,486,612 issued Dec. 30, 1969 to Kivell. Both of these structures, while eliminating the wooden slats of reinforcements heretofore mentioned, obtained their cushioning at the expense of having to use many cardboard padded pieces placed at the various critical positions within the package for cushioning that portion of the bathtub during a shipment. Such multi-piece packages were not easily assembled and were expensive to construct. V

A somewhat difiei'ent approach was attempted in the U.S. Pat. No. 3,521,744 issued July 28, 1970 to Smith wherein the patentee attempted to achieve the neces sary structural stability by using an elongated wooden rod at the lower rear feet of the tub in combination with a partial wooden end frame and a paperboard overlay ing tube in combination with previously tried card- I 2 board cushions. This design, like other attempted designs using wood framing, was still expensive to manufacture and did not provide the ultimate in a desired shipping container from the consumers standpoint.

SUMMARY OF THE INVENTION In order to overcome the problems inherent in the beforementioned prior art shipping packages, there is provided by the subject invention a new and novel bathtub shipping package which comprises a generally three-piece construction comprising a wrap-around tube member for completely encircling the bathtub used in conjunction with a pair of end caps, the wraparound tube member and the end caps are formed entirely of paperboard and may be coated on at least one side thereof with a water-proof coating for protection against the elements. The tube member is formed such that a structural paper manufactured joint is positioned beneath the rear feet of the bathtub which serves to cushion the rear legs whenever the bathtub is placed within the tube member and also serves as a means for reinforcing the tube member from longitudinal shock occurring during assembly of the package and occurring during transit.

The paper end caps have formed thereon paper means for reinforcing the end caps from both horizontal and vertical shock and a portion of the end caps have formed thereon protective pads for protecting the top end portions of the bathtub whenever the bathtub is placed within the packagepThe front panel of the wrap-around tube also contains holes which may be used for identifying the color of the bathtub contained within the package and the end caps contain a plurality of hand holes which may be utilized to lift the package and bathtub contained therein.

Accordingly, it is an object of the invention to provide a new and novel bathtub package which may be constructed in a basic three-piece package comprising a wrap-around paperboard tube and a pair of paperboard end caps with the end caps containing interval reinforcing means for reinforcing the end cap from horizontal and vertical shock and also containing built in pads for reinforcing the tub which is positioned on the pad when the package is assembled.

Yet another object of the invention is to provide a new and improved paperboard bathtub container wherein a longitudinal structural manufactured paper joint is formed beneath the rear portion of the tub feet to provide structural rigidity to the package and to eliminate the use of wooden reinforcing rods heretofore used.

Still another object of the invention is to provide a new and improvedpaperboard bathtub package which may be constructed entirely of weather-resistant coated paperboard and which completely enclosed the bathtub contained therein thereby allowing the bathtub package and bathtub to be stored outdoors without detrimental effect on the package or the bathtub.

Still yet another object of the invention is to provide an improved end cap for a wrap-around bathtub package wherein the end cap is formed in a one-piece construction with built in reinforcing means and built in cushioning means which are formed thereon without the use of outside fastening means such as glue, staples V or the like.

Yet another object of the invention is to provide a new and improved method for assembling a package around a bathtub which allows the bathtub to be quickly packaged with a minimum of handling of the heavy bathtub during the packaging process.

These and other objects and advantages of the invention will become apparent after a study of the drawings and after reviewing the specification describing the preferred embodiment.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. I is an exploded perspective view of the new and improved bathtub package of the invention showing the bathtub contained within the wrap-around tube member and showing one end cap in position prior to insertion into the tube member;

FIG. 2 is a top view of the production blank of the wrap-around tube member shown manufactured as a one-piece construction;

FIG. 3 is a top view of the production blank for one of the end caps of the invention;

FIG. 4 is a perspective view showing one of the end caps of the invention prior to forming the end cushions of the invention;

FIG. 5 is a perspective view of the end cap shown in FIG. 4 showing the end cushion being partially folded;

FIG. 6 is a perspective view of the end cap shown in FIGS. 4 and 5 showing the final stages of folding the end cushion;

FIG. 7 is a perspective view of the end cap shown in FIGS. 4-6 showing the end cushion completely folded and locked in place;

FIG. 8 is a perspective view of the bathtub package of the invention showing both end caps in position within the wrap-around tube member;

FIG. 9 is an end sectional view taken along line 9-9 of FIG. 8 showing the wrap-around tube completely encircling the tub and showing the folding sequence of the end caps in conjunction with the longitudinal manufactured joint;

FIG. 10 is a partial end section view taken along line I0I0 of FIG. 9; I

FIG. 11 is a partial end sectional view taken along line Illl of FIG. 9; and I FIG. 12 is a partial end sectional view taken along line l2l2 of FIG. 9.

DESCRIPTION OF THE PREFERRED EMBODIMENT Referring now to the drawings in general and particularly to FIG. I of the drawing there is shown the new and improved bathtub package of the invention which comprises a wrap-around tube member, shown generally by the numeral 10 which is formed from corrugated paperboard and comprises a bottom panel 12 which is hingedly attached to a front panel 14 by means of the scoreline H6. The front panel 14 has formed therein a plurality of identifying holes 18 which are used as means for identifying the color of the bathtub and 40 formed by means of the scorelines 42 and 44. In a similar manner the top panel 22 and the back panel 26 have formed on the. upper and lower portions thereof first hinged tabs 46, 48, 50 and 52 formed by means of the scorelines 54, 56, 58 and 60.

In addition to the first hinged tabsthusly mentioned, the bottom panel 12 and the back panel 26 also have formed on the ends thereof a second hinged tab 62 and 64 formed by means of the scorelines 66 and 68. It should be noted in the embodiment shown that the width of the second hinged tab 64 shown by the arrow dimension 70 is preferrably in the range of 7 inches more or less in order that the second hinged tabs 64 will be positioned beneath the tub feet 72 whenever the bathtub is positioned within the bathtub package as will be more fully explained hereinafter.

The first hinged tabs 30, 32, 38, 40, 46, 48, 50 and 52 are formed with chamferred sides 75, 77, 79, 81 83, 85, 87, 89, 91, 93, 95, 97, 99, 101, 103 and 105. The tube member 10 may be constructed in a one-piece configuration shown in FIG. 2 or may be constructed in several pieces within the spirit and scope of the invention, by providing manufactured joints at the foldlines 16, 24 or 28. Referring now to FIGS. 1 and 3 of the drawing there is shown the new and improved end cap, shown generally by the numeral 76 which is formed from a generally four-sided paperboard end member 78 having formed around the edges thereof a bottom flap 80, a top flap 82, a rear flap 84 and a front flap 86 for the purposes of which will be described more fully hereinafter. The bottom flap is hingedly attached to the end member 78 by means of the scoreline 88 and the top flap 82 is hingedly attached in a similar manner to the end member 78 by means of the scoreline 90. The rear flap 84 and the front flap 86 are hingedly attached to the end members 78 by a plurality of slit hinges which are formed by means of a plurality of die cuts 92 in combination with a plurality of scorelines 94 as is well known in the art of packaging.

The end members 78 also have formed in the central portion thereof a plurality of hand holes 96 which may be used to lift the assembled bathtub package. It will be understood that the bathtub package shown comprises two end caps 76 which are identical in construction with one cap being the reverse or opposite hand of the other end cap.

Returning now to FIG. 3 of the drawing there is shown generally by the numeral 98, the means for cushioning the top ends of the tub whenever the bathtub is positioned within the package. The cushioning means comprises a plurality of flaps 100, 102, 104 and 106 which are hingedly attached to each other and to the top flap 82 by means of a plurality of slit hinges 108, 110, 112, 114, 116, 118, 120, and 122 formed in a manner similar to the slit hinges formed on the rear flap 84 and the front flap 86 as before mentioned. The flap 102 has formed on one side thereof at 124 and 126 a protuberance which is designed to lock the flaps in position whenever they are folded up to form the cushion as will be more fully described hereinafter.

Referring now to FIGS. 4-7 of the drawing there is shown the manner in which the flaps 100, 102, 104 and 106 are used to provide a built-in cushion for support of the top portion of the tub whenever the tub is placed within the package. When the end cap 76 is folded for insertion into the tube member 10, the rear flap 84 and the front flap 86 are folded in juxtaposition with the end member 78 as shown in FIG. 4 of the drawing. Thereupon flap 106 is folded in juxtaposition with flap 104 completing the first step in the folding sequence. Thereafter the two flaps 104 and 106 are folded over on to flap 102 as shown in FIG. 5 of the drawing. The three flaps 102, 104 and 106 are then folded over the flap 100 as shown in FIG. 6 of the drawing with the final folding sequence being the folding of flaps 100, 102, 104 and 106 into juxtaposition with the top flap 82 as shown in FIG. 7 of the drawing. In the final folded position the protuberance I24 and 126 is positioned as shown in FIG. 7 and serves to lock the folded flaps 100, 102, 104 and 106 tightly into position as a single cushion having five thicknesses of paperboard.

When the rear flaps 84 and the front flap 86 are folded in juxtaposition to the end member 78 as shown in FIG. 7 these flaps provide additional strength to the end caps to reinforce the end cap from vertical shocks encountered in stacking of one bathtub container on the other container. In addition the folding of these flaps against the end member 78 also provides rotational rigidity to the end cap since the bottom edges 130 and 132 of the rear flap 84 and the front flap 86 is also positioned against the top flap 82 with the rear flap 84 and the front flap 86 being tightly held against the end member 78 by means of the rolled up cushion as shown in FIG. 7 of the drawing.

In assembling the bathtub package, the bathtub 20 is placed upside down with its top edge 128 lying on the top panel 22 of the tube member I0. Thereupon the back panel 26 is folded over the back of the tub and the front panel 14 is folded over the front of the tub with the bottom panel 12 overlaying the bottom of the tub which in the position shown in FIG. 9 of the drawing and is lying upside down within the tube member 10. Thereafter the cushions in the end caps are folded as before described and the top flap 82 is placed in juxtaposition to the top panel 22 with the ends of the tub being lifted a sufiicient amount to rest on the top of the cushion as shown in FIG. 10 of the drawing.

Referring now to FIGS. 11 and 12 of the drawing there is shown partial sectional views, enlarged for the purposes of clarity, showing the folding of the bottom flap 80 in place beneath the bottom panel 12 prior to the end cap being stapled to the tube member by means of the staples as at 136. The second hinged tab 64 which forms part of the manufactured longitudinal joint of the tube member 10 has been positioned around the tube as before mentioned. After the end caps 76 are positioned underneath the top of the tub with the cushioning supporting the top edge 128 of the tube as shown in FIG. 10, the bottom flap 80 of the end cap 76 is then positioned between the second hinged tab 64 and the bottom panel 12. Thereafter the first hinged tab 32 is folded down over the end member 78 and a plurality of staples are applied at 136 throughout the length of the first hinged tab 32. When the comer is erected thusly and second hinged tab 64 is able to resist the horizontal forces caused when applying the staples at 136. In a similar manner the opposite end of the package is completed with the first hinged tabs 30 being positioned and stapled in a similar manner.

Referring to FIG. 12 of the drawing there is shown the folding sequence of the front flap 86 and its hinged bottom flap 134 which is hinged by means of the scoreline 135. As before mentioned the front flap 86 has been folded inwardly in juxtaposition to the end memher 78 and the flap 134 has been hinged at right angles to the front flap 86 as shown in FIG. 12. Thereafter the bottom flap 80 is positioned beneath the bottom panels 12 as shown in FIG. 12 and the first hinged tab 32 is folded downwardly over the end member 78 and a plurality of staples are applied through the length of the first hinged tab 136; In a similar manner th opposite end of the bathtub package is stapled shut with a plurality of staples also being applied to the remaining first hinged tabs 38, 40, 46, 48, 50 and 52 after these tabs have been folded down over the end cap as shown in FIG. 8 of the drawing. Thereupon the assembler of .the package may wish to applya plurality of staples at 138 along the longitudinal manufactured joint along the length of the tube member 10 as shown in FIG. 9 of the drawing.

When the bathtub package has been constructed and assembled as hereinbefore described the second hinged tabs 62 and 64 form a longitudinal manufactured joint which runs the length of the tube member 10 with the tab 64 serving as cushioning for the tub feet 72 and also serving to longitudinally reinforce the tube member from shock occurring during the stapling of the end caps to the tube member. The new and improved end caps thusly formed may be constructed from waterresistant coated paperboard and contain built-in protective pads for protecting the upper edge of the bathtub contained within the bathtub pack. When the package is constructed in the manner described no wooden reinforcements are required for the bathtub package and several bathtubs may be packed vertically on top of each other without damage to the lower packages. It has been found from experimentation that when the bathtub package is constructed with the tube member being formed of 200 lb. double-wall paperboard and the end caps being formed of 350 lb. double-wall paperboard, a highly desired package is obtained which has abilities to protect the vital areas of the bathtub and also to withstand standup end drops which occur in the field storage of the bathtubs within the package. By the use of the built-in rollup cushioning pads on the end caps, the cushions are always rigidly held in place on the end caps and the entire package may be quickly assembled around the bathtub and securely fashioned into a, tight compact protective package. When the package is thusly formed and the paperboard members have been coated with a weather-resistant material, the assembled package may be stored in outside storage areas without damage to the package or to the contents contained within the package. With the utilization of the color identifying holes contained in the front panel of the tube member, the color of the bathtub contained within the enclosed package may be readily ascertained without relying oncolor code numbers or oher printing indicia designating the color contained on the package.

Having described the invention, I claim:

1. In the formation of a bathtub package of the type having a wrap-around tube member completely encircling the bathtub, the tube member comprising a bottom panel, a front-panel, a top panel, a back panel and a longitudinal second hinged tab formed on the back and bottom panel, the package further having positioned in each end of the tube an end cap having at least one generally horizontal bottom flap formed thereon, the improvement comprising:

a. positioning a portion of one of the longitudinal second hinged tabs in juxtaposition and below the generally horizontal bottom flap formed on each end cap;

b. positioning the bottom panel in juxtaposition and above the generally horizontal bottom flaps; and

c. fastening the ends of the bottom panel to the end caps; the back panel and the positioned second hinged tab serving as a means to resist the stapling force at one corner portion of the tube member.

2. The improvement as defined in claim 1 further comprising the step of fastening the bottom panel to the second hinged tab, formed on the back panel, along the length of the tub package.

3. A method of assembling a three-piece bathtub package comprising the steps of:

a. providing a pre-cut tube blank having a bottom panel, a front panel, a top panel and a back panel and a pair of pre-cut structurally supporting end caps, each end cap having a generally horizontal bottom flap formed thereon and the tube blank having a longitudinal second hinged tab formed on the back and bottom panel;

b. laying the tube blank on a flat surface;

c. positioning the bathtub upside down on top of the tube blank;

d. positioning a portion of one of the longitudinal second hinged tabs in juxtaposition and below the generally horizontal bottom flap formed on each end cap;

e. positioning the bottom panel in juxtaposition and above the generally horizontal bottom flaps; and f. fastening the ends of the bottom panel to the end caps; the back panel and the positioned second hinged tab serving as a means to resist the stapling force at one comer portion of the tube member.

P0405J UNITED STATES PATENT OFFKCE CERTIFICATE OF CORRECTION Patent No. 3,813,844 I Dated June 4, 1974 Inventor) ett A. Coons, Lewis D. Poggiali, Richard P. Jacalone It is certified that error appears in the aboveidentified patent 'and that said Letters Patent are hereby corrected as shown below:

Column 5, line 52,' change "tube'Pto -tub--. Column 5, line 58, after "and" insert --the--. Column 6, line 7, change "th" to --the--. Co1 umn 6,- line 54 ehange "oher" to --other-.

Signed and sealed this 5th day of November 1974.

(SEAL) Attest:

McCOY M. GIBSON JR. 0. MARSHALL DANN Attesting Officer commissioner of Patents 

1. In the formation of a bathtub package of the type having a wrap-around tube member completely encircling the bathtub, the tube member comprising a bottom panel, a front panel, a top panel, a back panel and a longitudinal second hinged tab formed on the back and bottom panel, the package further having positioned in each end of the tube an end cap having at least one generally horizontal bottom flap formed thereon, the improvement comprising: a. positioning a portion of one of the longitudinal second hinged tabs in juxtaposition and below the generally horizontal bottom flap formed on each end cap; b. positioning the bottom panel in juxtaposition and above the generally horizontal bottom flaps; and c. fastening the ends of the bottom panel to the end caps; the back panel and the positioned second hinged tab serving as a means to resist the stapling force at one corner portion of the tube member.
 2. The improvement as defined in claim 1 further comprising the step of fastening the bottom panel to the second hinged tab, formed on the back panel, along the length of the tub package.
 3. A method of assembling a three-piece bathtub package comprising the steps of: a. providing a pre-cut tube blank having a bottom panel, a front panel, a top panel and a back panel and a pair of pre-cut structurally supporting end caps, each end cap having a generally horizontal bottom flap formed thereon and the tube blank having a longitudinal second hinged tab formed on the back and bottom panel; b. laying the tube blank on a flat surface; c. positioning the bathtub upside down on top of the tube blank; d. positioning a portion of one of the longitudinal second hinged tabs in juxtaposition and below the generally horizontal bottom flap formed on each end cap; e. positioning the bottom panel in juxtaposition and above the generally horIzontal bottom flaps; and f. fastening the ends of the bottom panel to the end caps; the back panel and the positioned second hinged tab serving as a means to resist the stapling force at one corner portion of the tube member. 